MIT Product Design course web siterao/DFM - 00A Project.pdf · Product Design Phase • Product Generation – Usable Off-the-Shelf Products – Shape Development Driven by Function

1

330:135g Design for Manufacturing

Dr. Nageswara Rao Posinasetti

January 14, 2008 Posinasetti Nageswara Rao 2

MIT Product Design course web site

• http://web.mit.edu/2.009/www/fall2001/pages/gallery_frameset.htm

Snow Blower

Little Green wagon

Folding scooter

2


Product Development Process

• Identify customer needs• Establish target specifications• Generate product specifications• Select product concepts• Test product concepts• Set final specifications• Plan manufacturing process


Goals of customer need identification

• Ensure that the product is focused on customer needs

• Identify latent or hidden needs as well as explicit needs

• Provide a fact base for justifying the product specification

• Create an archival record of the needs activity of the development process

• Ensure that no critical customer need is missed or forgotten

• Develop a common understanding of customer needs among members of the development team


Identify customer needs

• Gather raw data from customers• Interpret the raw data in terms of

customer needs• Organize the needs into primary,

secondary and tertiary needs• Establish the relative importance of the

needs• Reflect on the results and the process

3


Gather raw data from customers

• Interviews– Audio recording– Notes– Video recording

• Focus groups– Group of 8 to 12 customers

• Observing the product in use• Written survey


Interpret the raw data in terms of customer needs

• Express the need in terms of what the product has to do, not in terms of how it might do it.

• Express the need as specifically as the raw data

• Use positive, not negative phrasing• Express the need as an attribute of the

product.


Establish target specifications

• Prepare the list metrics, using the needs metrics, if necessary

• Collect the competitive benchmarking information

• Set ideal and marginally acceptable target values for each metric

• Reflect the result and the process

4


Problem

• A successful hand tool manufacturer is exploring the growing market for hand-held power tools

• After the initial research, the firm decided to enter the market with a cordless screwdriver



5




6




7




Project team

• Product Manager (Leader)• Product Design Engineer• Designer/drafter• Manufacturing Manager

8


Project team

• Product Manager: The Product Manger is an individual appointed by the CEO from his/her staff for a particular product development.

• The Product Manager will, throughout the project, have the primary responsibility for the performance of the product development and conformance with the product needs. He/she is responsible for the Product Development File.


Project team

• Product Design Engineer: The Product Design Engineer is an individual appointed by the CEO from his/her staff for a particular product development.

• The Product Design Engineer will have primary responsibility for the design of the product, to release to production (assuming the product reaches production).


Project team

• Designer/drafter: The Designer/drafter is responsible for the documentation of the design.

• This includes all drawings of the design, parts lists, and Product Changes Notices (PCNs).

• He/she is also to assist of the Product Design Engineer in the development of the design.

9


Project team

• Manufacturing Manager: The Manufacturing Manager is responsible for assurance that the design is manufacturable.

• Additionally, he/she is responsible for developing Process Instructions for the assembly of the device.

• If manpower is limited, then the duties of the Manufacturing Manager will be combined with those of the Designer/drafter.


Product Development Report

• This is a group produced file covering the history of the design.

• Documents that should be in the Product Development File are:


Problem Appraisal Phase

• Understanding the Problem– Description of Customers– Customer's Requirements– Weighting of Customer's Requirements– Competition's Benchmarks Versus Customer's

Requirements– Engineering Requirements– Competition's Benchmarks Versus Engineering

Requirements– Engineering Targets

To be completed by Feb. 11th

10


Problem Appraisal Phase

• Planning the Project– Task Titles– Objectives of each Task– Personnel Required for Each Task– Time Required for Each Task– Schedule of Tasks

To be completed by Feb. 18th


Conceptual Design Phase

• Concept Generation– Functional Decomposition– Literature and Patent Search Process and

Results– Function-Concept Mapping– Sketches of Overall Concepts

To be completed by March 24th


Conceptual Design Phase

• Concept Evaluation• Assessment of Technology Readiness

– Identification of Failure Modes– Identification of Critical Parameters

• Concept Selection– Decision Matrices to Determine Best Concepts– Analysis, Experiments and Models Supporting

Evaluation

To be completed by April 7th

11


Product Design Phase

• Product Generation– Usable Off-the-Shelf Products– Shape Development Driven by Function– Material(s) Selection– Manufacturing Process(s) Selection

To be completed by April 14nd



• Product Evaluation– Comparison to Engineering Requirements– Functional Changes Noted– Design for Assembly Evaluation– Cost Evaluation– Analysis, Experiments and Models

Supporting Evaluation




• Final Product Documentation– Layout Drawings– Detail Drawings of Manufactured Parts– Parts List (Bill of Materials)– Assembly Instructions


12

Questions and Comments